Feed control for operationally programmed sewing machine

ABSTRACT

The speeds at which material is advanced by the feed mechanism of a sewing machine, is automatically programmed during a controlled sewing cycle. The sewing cycle is initiated in delayed response to detection of the material by a sensor as the material approaches the presser foot. Selectively timed pauses in the sewing cycle enables the operator to reposition the work or perform other functions as well as to accommodate automatic changes in feed rate.

United States Patent Furnari Mar. 26, 1974 [5 FEED CONTROL FOR OPERATIONALLY 3,611,961 10/1971 Lopez et a1. 112/121.11

PROGRAMMED SEWING MACHINE 3,363,594 1/1968 Kosrow 3,687,097 8/1972 Kosrow et al.... [75] Inventor: Anth ny F r r lndlana, 3,074,632 l/l963 Braun et a1. 112/121.11 x

[73] Assignee: Campus Sweater & Sportswear C0.

Primary ExaminerJames R. Boler [22] Flled: Sept- 1972 Attorney, Agent, or FirmClarence A. OBrien; Har- 21 Appl. No.: 291,339 vey Jacobson A D Related U S ppllcatlon ata ABSTRACT [63] Continuation-impart of Ser. No. 216,457. Jan. 10,

1973, The speeds at-whlch material is advanced by the feed mechanism of a sewing machine, is automatically pro 52 us. (:1. 112/121.11, 112/210 grammed during a controlled sewing y The [51] Int. Cl D05b 19/00 ihg Cycle is initiated in delayed response to detection 58 Field of Search..... 112/121.11, 121.12, 121.15, of the material y a sensor as the material approaches 1 12/l21.29, 210, 262, 203, 2- the presser foot. Selectively timed pauses in the sewing cycle enables the operator to reposition the work 56] References Ci d or perform other functions as well as to accommodate UNITED STATES PATENTS automatic changes in feed rate.

3,613,608 10/1971 Hinerfeld et a1 112/2 12 Claims, 4 Drawing Figures PAIENIEB mas m4 SHEEI 2 OF 2 MM QQ Y mg This invention relates in general to control systems for sewing machines and in particular to a system through which the operator is relieved of various functions in the manufacture of garments. This application is a continuation-in-part of my prior co-pending application U. S. Ser. No. 216,457, filed Jan. 10, I972.

The control system disclosed in my prior co-pending application, involves initiation of a sewing cycle in response to detection of material by a sensor as the material is being manually advanced toward the presser foot. The signal initiating the sewing cycle is delayed to permit automatic raising of the presser foot and lowering thereof once the material is positioned thereunder. During the sewing cycle an operating solenoid is energized to operate the drive mechanism of the sewing machine. By means of a programming control component, the sewing cycle may be interrupted intermittently for intervals of preselected duration in order to enable the operator to perform various functions on the garment being sewn such as repositioning of the work. During such pauses in the sewing cycle, it is sometimes desirable to change the material feed rate in order to provide fullness in certain areas of garment construction. This function has until now been effected manually by the operator. However, changing the material feed rate manually introduces non-uniformity in the construction of garments, reduces production rates, and is a source of operator fatigue.

It is therefore an important object of the present in vention to provide an improved control system for industrial types of sewing machines in which the material feed rate may be automatically changed in accordance with a preselected program during an automatically initiated sewing cycle, in order to produce a completely and uniformly tailored product of high quality.

In accordance with the present invention, the control system for an industrial sewing machine such as disclosed in my prior co-pending application, aforementioned, is provided with a sew and pause programmer through which pauses of preselected duration are programmed into the sew cycle with facilities for preselecting certain material feed rates operative during different sew periods of the cycle. Changes in feed rate are effected by signals generated during certain sewing periods in the sewing cycle, such feed control signals being operative through solenoids to extend selected stop elements for limiting the position to which a feedin control lever is biased. The sewing machine is of a type in which the feed rate may be adjusted manually by such a feed-in control lever.

These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.

FIG. 1 is a side elevational view ofa typical industrial sewing machine having the automatic feed rate control of the present invention.

FIG. 2 is a schematic block diagram illustrating the control system of the present invention.

FIG. 3 is a front elevational view of the programmer console.

FIG. 4 is an electrical circuit diagram associated with the programmer.

Referring now to the drawings in detail, FIG. 1 illustrates a typical industrial sewing machine generally referred to by reference numeral 10. The sewing machine includes the usual work supporting table 12 positioned above the floor by a base frame 14. Material is advanced along the work table under the reciprocating needle by the usual material feed device 16 underlying the usual presser foot 18 at one end of the machine head 20. The feed rate of the material is controlled by the position of an upwardly biased feed adjustment control lever 22. Sewing machines having such feed adjustment facilities are well known, as disclosed for example in U. S. Pat. No. 2,258,487 to Garwin. Further, operation of the sewing machine 10 may be controlled by a system of the type disclosed in my prior copending application, aforementioned with respect to initiation and termination of the sewing cycle.

FIG. 2 diagrammatically illustrates the drive mechanism 24 associated with the sewing machine that is operated under control of a sewing cycle control component 26 of the type disclosed in my prior co-pending application, aforementioned. A material sensor 28 is associated with the control component 26 for detecting material being advanced toward the presser foot in order to produce a sew signal in delayed response to detection of material approaching the presser foot. This sew signal is also applied through lines 30 as diagrammed in FIG. 2 to a sew and pause programmer 32 by means of which preselected pauses in the sewing cycle are produced. The programmer 32 is accordingly connected to the sewing cycle control component 26 for this purpose and is also connected to a feed rate control component 34 through which the feed adjusting control lever 22 is repositioned to change the feed rate.

The programmer 32 may be housed in a console 36 as shown in FIG. 3. The front panel of the console is provided with a top row of control knobs 38 for regulating the duration of the sewing periods while the lower row of control knobs 40 adjust the duration of the pause periods. Indicator lamps 42 signify the cycle phase. The programmer is designed to provide differently timed programming signals for sewing left and right lines of stitching on a garment during a sewing cycle and may be normally switched from one timing cycle to another at any time by actuation of a reverse switch 44. An on-off switch 46 is provided and a multipin connector socket 48 through which the programmer is electrically connected by a cable 50 to the feed rate control 34 mounted below the work table 12 as shown in FIG. 1. Feed rates are selected through four control knobs 51. a

With reference to FIG. 1, the feed rate control 34 includes a plurality of valve controlling solenoids 52, four of such solenoids being shown in the illustrated embodiment. Each of the solenoids operates a valve through which a fluid, such as air under pressure, is supplied by fluid lines 54 to corresponding fluid cylinder devices 56 from which piston rod stop elements 58 are projected when associated solenoids 52 are energized. The cylinder devices 56 are fixedly mounted in vertical spaced relation below the work table 12 by a bracket frame 60 provided at its lower end below the cylinder devices with a pivot assembly 62. The pivot assembly hingedly mounts a position limiting plate 64 to which an arm 66 is connected. The arm 66 is in turn connected by a link 68 to the feed control lever 22 aforementioned. Since lever 22 is biased upwardly as viewed in FIG. 1 it will be urged to a position determined by the stop element 58 projected from one of the cylinder devices 56. When all of the stop elements are retracted, the lever 22 will be in its uppermost position. The lever 22 will be displaced downwardly or counter clockwise as viewed in FIG. 1 by an amount depending upon which of the cylinder devices 56 projects its stop element. Selection of the cylinder device 56 to determine the position of control lever 22 and the feed rate adjusted thereby, is effected through energization of the solenoids 52 to which electrical signal energy is supplied by cable 50 from the programmer 32.

Referring now to FIG. 4, the programmer 32 in the illustrated embodiment, is supplied with electrical energy from a 120 VAC source through power lines 70 and 72, upon closing of on-off switch 46. When power is on, the pilot lamp 74 is illuminated and a full wave rectifier 76 is energized to supply a reduced DC voltage across lines 78 and 80.

As hereinbefore indicated, the drive mechanism for the sewing machine is operated through a solenoid, the energizing .circuit of which is normally completed through a pair of relay switches 82 as shown in FIG. 4. These relay switches are opened in response to a stop signal to produce a pause in the sewing cycle by energization of the relay coil 84, one terminal of which is connected to the power line 70. The other terminal of the relay coil 84 is connected by line 86 to the interconnected contacts 88 in a pause bank section 90 of a stepping switch assembly wherein the stop signals are generated. The pause bank section 90 includes a moving contact arm 92, that is connected by line 94 to the power line 72 so as to energize relay coil 84 whenever the contact arm engages one of the contacts 88 thereby opening relay switch 82 to produce a pause period in the sewing cycle. The contact arm 92 is incrementally advanced between operative positions by a stepping coil 96 connected to the DC voltage line 78 through voltage reducing resistor 98. The stepping coil is also connected through a relay switch 100 of time delay relay 118 and conductor 102 to the movable contact arm 104 of a timing bank section 106 of the step switch assembly. When the contact arm 104 engages one of the operative contacts 108, a circuit is completed for the stepping coil through one of two adjustable resistors 110 and 112 in series with a reversing relay switch 114 and relay switch 116 of the time delay relay 118. Resistors 110 associated with the respective contacts 108 are connected through line 120 to one contact 122 engageable by relay switch 114, the other relay contact 124 being connected by line 126 to the other adjustable resistors 112. It will therefore be apparent that when contact arm 104 engages one of its contacts 108, the stepping coil 96 will be connected in series with one of the resistors 110 or 112 to voltage line 80 to control the rate at which capacitor 128 is charged and alternately determine the duration of the sew and pause periods by controlling the pulsing of the stepping coil 96. The capacitor 128 is connected in series with discharge resistor 130 to the negative voltage line 80.

The time delay relay 118 includes a relay coil 132, one terminal of which is connected to power line 72 through an interrupter switch 134. The other terminal of relay coil 132 is connected to power line 70 through either normally opened relay switch 136 of a signal relay 138 or through the switch 140. The switches 134, 140 and 141 are actuated each time the stepping coil 96 is pulsed. When a sew signal derived from the sewing cycle control component 26 is applied through lines 30 to the relay coil 142 of the signal relay, it closes relay switch 136 thereby energizing coil 132 in the time delay relay. A timing cycle is thereby initiated during each pause period at the end of which relay switch is actuated to by-pass the timing circuit established through timing section 106. Relay switch 116 is also opened at the end of the timing cycle to disconnect the timing circuit. The timing cycle of the time delay relay coil 132 is restarted by deenergization thereof through the interrupter switch 134 opened each time the stepping coil 96 is pulsed. The time delay relay 118 is thus operative to prevent the step switch assembly from reversing unintentionally.

After the step switch has been advanced two increments from its home position, the contact arm 144 in the home bank section 146 will engage one of the contacts 148 so as to by-pass the timing circuit when the signal relay coil 142 is deenergized at the end of a sewing cycle, restoring its relay switch 150 to the position shown in FIG. 4. The step switch is thereby rendered operative in conjunction with switches and 141 to rapidly return the contact arms to the zero or home positions. During the sewing cycle, however, relay switch engages its other contact so as to disconnect the contacts 148 from the voltage line 80 through relay switch 116.

The power line 70 is also connected to the contact arms 154 and 156 in the auxiliary bank section 158 and signal bank section 160 of the step switch assembly. Thus, as contact arm 154 is advanced to certain positions, current will be supplied through one of four conductors 162 to an associated relay switch 164 engageable with one of two contacts 166 and 168 to which a pair of ganged selector switches 170 and 172 are connected, a pair of such switches being associated with each of the four control knobs 51 aforementioned. Depending upon the position of the control knobs 51, a selected one of the valve solenoids 52 in the feed rate control 34 will be energized during each of four phases in the sewing cycle. A different feed rate sequence may be effected through the setting of the control knobs 51 depending on the position of the reversing relay switches 164. It will also be appreciated that conductors 162 conduct current when the contact arm 154 engages contacts 174 corresponding to sew periods in order to energize selected solenoids 52 during the sew periods.

The programmer component automatically changes the timing program by displacement of the relay switches 114 and 164 by means of a latching relay coil 176 connected across the power lines 70 and 72 through a normally opened relay switch 178 that is closed during a sewing cycle by a signal relay coil 180 connected to the sew signal lines 30. Pulsing of the relay coil 176 may be effected at any time by manual actuation of the reverse switch 44, by-passing relay switch 178. A pair of indicator lamps 182 and 184 are illuminated under control of relay switch 186 to signify the condition of the reversing control relay.

The phase of the programmer is indicated by means of the signal bank section 160 of the step switch assembly which includes a plurality of contacts 188 engaged by the contact arm 156 to illuminate a corresponding indicator lamp 42. The final contact 188 is also connected by line 190 to the relay switch 178 to automatically pulse the reversing relay coil 176 at the end of the last pause position of the step switch assembly. The step switch will then begin another timing cycle in a reverse direction provided the timing cycle of the time delay relay 118 is completed before the last pause position is reached.

It will be apparent from the foregoing that the programmer 32 may be preset to interrupt a sewing cycle several times with pause periods of preselected duration to meet varying operator capabilities and work requirements. Also, preselected feed rates may be set in a selected sequence by the control knobs which will be repeated for every garment sewn to achieve automatic and uniform tailoring of the product.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

What is claimed as new is as folows:

1. In combination with a sewing machine having a drive mechanism and a material feed device driven thereby in one direction at an adjustably regulated feed rate, material sensing means for detecting the presence of material being advanced toward the feed device in said one direction, automatic control means connected to the drive mechanism for operating the machine during a sewing cycle while the material is detected by the sensing means, programming means connected to the control means for intermittently generating a stop signal interrupting operation of the machine during the sewing cycle, and feed rate control means connected to said material feed device for changing the rate at which the material is fed in said one direction in response to said stop signal from the programming means.

2. In combination with a sewing machine having a drive mechanism and a material feed device driven thereby in one direction at an adjustably regulated feed rate, material sensing means for detecting the presence of material being advanced toward the feed device in said one direction, automatic control means connected to the drive mechanism for operating the machine during a sewing cycle while the material is detected by the sensing means, programming means connected to the control means for intermittently generating a stop signal interrupting operation of the machine during the sewing cycle, and feed rate control means connected to said material feed device for changing the rate at which the material is fed in said one direction in response to said stop signal from the programming means, said feed device including a feed-in control lever biased in one direction, said feed rate control means including a plurality of retractable stop elements, position limiting means movably mounted for engagement by said stop elements when extended to limit movement of the control lever in said one direction to preselected positions, power operated means for extending said stop elements, and means connecting the power operated means to the programming means for selecting the stop elements extended in response to said interruptions in the sewing cycle.

3. The combination of claim 2 wherein said position limiting means comprises a plate, means pivotally mounting the plate in fixedly spaced relation to said stop elements, and linkage means connecting the plate to the control lever.

4. The combination of claim 3 wherein said pivotal mounting means includes a frame fixedly mounting the power operated means in spaced relation to the plate.

5. In combination with a sewing machine having an adjustably positioned feed control for changing rate of feed in one direction, means for intermittently generating a stop signal interrupting operation of the sewing machine during a sewing cycle, and feed rate control means responsive to said stop signal for automatically changing the position of the feed control.

6. In combination with a sewing machine having an adjustably positioned feed control and means for intermittently interrupting operation during a sewing cycle, feed rate control means responsive to said interruptions for automatically changing the position of the feed control, said feed rate control means including a plurality of retractable stop elements, position limiting means movably mounted for engagement by said stop elements when extended to limit movement of the feed control to preselected positions, power operated means for extending said stop eelements, and means for selecting the stop elements extended in response to said interruptions during pauses in the sewing cycle.

7. The combination of claim 6 wherein said position limiting means comprises a plate, means pivotally mounting the plate in fixedly spaced relation to said stop elements, and linkage means connecting the plate to the feed control.

8. The combination of claim 7 .wherein said pivotal mounting means includes a frame fixedly mounting the power operated means in spaced relation to the plate.

9. The combination of claim 8 including programming means for preselecting the intervals during the sewing cycle when operation is interrupted and the position of the feed control changed.

10. The combination of claim 6 including programming means for preselecting the intervals during the sewing cycle when operation is interrrupted and the position of the feed control changed.

11. In combination with a sewing machine having a drive mechanism rendered operative in delayed response to detection of material by a sensor to initiate a sewing cycle, means for operating the drive mechanism during said sewing cycle, signal controlled means connected to the sensor for energizing said operating means during said sewing cycle and programming means connected to the signal controlled means for temporarily deenergizing the operating means during pauses of preselected duration within the sewing cycle.

12. In a sewing machine having a power source and a stitching mechanism operated by said power source, the combination comprising a feeding mechanism driven by said power source for advancing material through said stitching mechanism, feed control means cooperating with said feeding mechanism for changing the rate of feed of the material in one direction, timing means connected to said stitching mechanism for producing a stop signal upon elapse ofa preselected period of time, and circuit means interconnecting the timing means and the feed control means for automatically effecting said change in feed rate in reponse to said stop signal, said circuit means including means cooperating with the timing means for controlling a period initiated by the stop signal during which the feeding and stitching mechanism are inoperative.

l t I 

1. In combination with a sewing machine having a drive mechanism and a material feed device driven thereby in one direction at an adjustably regulated feed rate, material sensing means for detecting the presence of material being advanced toward the feed device in said one direction, automatic control means connected to the drive mechanism for operating the machine during a sewing cycle while the material is detected by the sensing means, programming means connected to the control means for intermittently generating a stop signal interrupting operation of the machine during the sewing cycle, and feed rate control means connected to said material feed device for changing the rate at which the material is fed in said one direction in response to said stop signal from the programming means.
 2. In combination with a sewing machine having a drive mechanism and a material feed device driven thereby in one direction at an adjustably regulated feed rate, material sensing means for detecting the presence of material being advanced toward the feed device in said one direction, automatic control means connected to the drive mechanism for operating the machine during a sewing cycle while the material is detected by the sensing means, programming means connected to the control means for intermittently generating a stop signal interrupting operation of the machine during the sewing cycle, and feed rate control means connected to said material feed device for changing the rate at which the material is fed in said one direction in response to said stop signal from the programming means, said feed device including a feed-in control lever biased in one direction, said feed rate control means including a plurality of retractable stop elements, position limiting means movably mounted for engagement by said stop elements when extended to limit movement of the control lever in said one direction to preselected positions, power operated means for extending said stop elements, and means connecting the power operated means to the programming means for selecting the stop elements extended in response to said interruptions in the sewing cycle.
 3. The combination of claim 2 wherein said position limiting means comprises a plate, means pivotally mounting the plate in fixedly spaced relation to said stop elements, and linkage means connecting the plate to the control lever.
 4. The combination of claim 3 wherein said pivotal mounting means includes a frame fixedly mounting the power operated means in spaced relation to the plate.
 5. In combination with a sewing machine having an adjustably positioned feed control for changing rate of feed in one direction, means for intermittently generating a stop signal interrupting operation of the sewing machine during a sewing cycle, and feed rate control means responsive to said stop signal for automatically changing the position of the feed control.
 6. In combination with a sewing machine having an adjustably positioned feed control and means for intermittently interrupting operation during a sewing cycle, feed rate control means responsive to said interruptions for automatically changing the position of the feed control, said feed rate control means including a plurality of retractable stop elements, position limiting means movably mounted for engagement by said stop elements when extended to limit movement of the feed control to preselected positions, power operated means for extending said stop eelements, and means for selecting the stop elements extended in response to said interruptions during pauses in the sewing cycle.
 7. The combination of claim 6 wherein said position limiting means comprises a plate, means pivotally mounting the plate in fixedly spaced relation to said stop elements, and linkage means connecting the plate to the feed control.
 8. The combination of claim 7 wherein said pivotal mounting means includes a frame fixedly mounting the power operated means in spaced relation to the plate.
 9. The combination of claim 8 including programming means for preselecting the intervals during the sewing cycle when operation is interrupted and the position of the feed control changed.
 10. The combination of claim 6 including programming means for preselecting the intervals during the sewing cycle when operation is interrrupted and the position of the feed control changed.
 11. In combination with a sewing machine having a drive mechanism rendered operative in delayed response to detection of material by a sensor to initiate a sewing cycle, means for operating the drive mechanism during said sewing cycle, signal controlled means connected to the sensor for energizing said operating means during said sewing cycle and programming means connected to the signal controlled means for temporarily deenergizing the operating means during pauses of preselected duration within the sewing cycle.
 12. In a sewing machine having a power source and a stitching mechanism operated by said power source, the combination comprising a feeding mechanism driven by said power source for advancing material through said stitching mechanism, feed control means cooperating with said feeding mechanism for changing the rate of feed of the material in one direction, timing means connected to said stitching mechanism for producing a stop signal upon elapse of a preselected period of time, and circuit means interconnecting the timing means and the feed control means for automatically effecting said change in feed rate in reponse to said stop signal, said circuit means including means cooperating with the timing means for controlling a period initiated by the stop signal during which the feeding and stitching mechanism are inoperative. 